Contents 1

Foreword / v Preface i _ vii Acknowledgements \ '

1. Cement " j 1.1 1.1 Introduction 1.1 1.2 Basic Composition of Cement 1.1 1.3 Manufacture of Cement 1.2 1.4 Physical Properties of Cement 1.9 1.5 Chemical Properties of Cement 1.11

1.6 Heat of Hydration - - ^ ; ft - 1.13 1.7 Colour of Cement 1.13 1.8 Variety of Cement and their Applications 1.13 1.9 Storage of Cement r 1.21 1.10 Conclusion . . . 1.26

Appendix I 1.27 Appendix II 1.28 Appendix III ^ ^ 1.29

2. Mineral Admixtures 2.1 2.1 Introduction 2.1 2.2 Pozzolanic Reaction and Concrete 2.1 2.3 Fly Ash as Mineral Admixture in Concrete 2.1 2.4 GGBS in Concrete 2.7 2.5 Silica Fume in Concrete 2.12 2.6 Metakaolin in Concrete 2.16 2.7 Green, Durable and Economical Concrete with Fly Ash and GGBS 2.17

3. Water 3.1 3.1 Introduction 3.1 3.2 Quality of Water . 3.1

xii I Contents

4. Coarse Aggregate 4.1

4.1 Introduction 4.1 4.2 Classification of Aggregates 4.1 4.3 Properties of Coarse Aggregates Affecting Concrete Characteristics 4.5

5. Fine Aggregate . ; * I 5.1

5.1 Introduction 5.1 5.2 Grading of Fine Aggregate 5.1 5.3 Crushed Sand 5.4 5.4 Deleterious Material in Fine Aggregates 5.4 5.5 Fine Aggregate Requirement 5.4

6. Manufactured Sand as Fine Aggregate 6.1

6.1 Shortage of Natural Sand 6.1 6.2 Optimum Shape 6.1 6.3 Void Content 6.2 6.4 Manufacturing Process , , ^Vj 6.3 6.5 Optimal Process 6.4 6.6 Tests for Manufactured Sand 6.4

7. Use of Copper Slag as Fine Aggregate in Concrete 7.1

7.1 Introduction n 7.1 7.2 What is Copper Slag? 7.1 7.3 Concluding Remarks 7.8

8. Chemical Admixture 8.1

8.1 Definition 8.1 8.2 History 8.1

9. Concrete Mix Proportioning 9.1

9.1 Objectives 9.1 9.2 Principles of Concrete Mix Proportioning 9.1 9.3 Methods of Concrete Mix Proportioning 9.16

Annexure A 9.26 Annexure B 9.29 Annexure C 9.34 Annexure D 9.38

10. Concrete Production and Supply 10.1

10.1 Storage of Materials 10.2 10.2 Batching 10.7

Contents | xiii

10.3 Mixing Arrangements 10.8 10.4 Control Systems 10.8 10.5 Transportation 10.9 10.6 Batching Special Concrete / , j ; 10-9 10.7 Checklist for Various Items 10.10

11. Placing, Compaction and Curing of Concrete 11.1

11.1 Introduction 11.1 11.2 Placing of Concrete , |-- " • 11.1 11.3 Compaction of Concrete | 11-6 11.4 Curing of Concrete

12. Shrinkage and Creep

12.1 Introduction ^

^ 11.14

^ ^ V 12.1

12.1 12.2 Shrinkage ' 12.1 12.3 Creep 12.8

13. Strength and Durability of Concrete 13.1

13.1 Introduction 13.1 13.2 Strength of Concrete 13.2 13.3 Mechanical Properties of Hardened Concrete 13.10 13.3 Bond Strength of Concrete and Reinforcement Steel 13.30 13.4 Durability of Concrete 13.31

14. Reinforcement Cover and Corrosion 14.1

14.1 Introduction 14.1 14.2 The Corrosion Process " 14.1 14.3 Black Rust 14.4 14.4 Corrosion due to Carbonation 14.5 14.6 Corrosion due to Chloride Attack " 14.7 14.7 Measures for Reducing the Rate of Corrosion 14.8 14.8 Improving the Quality of Cover v 14.14

15. Concrete Resistance to Sulphate Attack 15.1

15.1 Introduction 15.1 15.2 Mechanism of Sulphate Attack 15.1 15.3 Mitigation of Sulphate Attack -s. . 15.2

16. Alkali Silica Reaction 16.1

16.1 Introduction 16.1 16.2 Mechanism of Alkali-silica Reaction 16.1

xiv I Contents

16.3 Tests for Alkali Reactivity of Aggregate 16.3 16.4 Mitigation Measures for Alkali-silica Reaction 16.5 16.5 Prevention/Minimizing ASR Effect on Concrete Structure 16.10

17. High Strength and High Performance Concrete 17.1 17.1 Introduction - 17.1 17.2 High Performance Concrete - Overview o'̂ 17.2 17.3 High Performance Concrete - Major Characteristics 17.2 17.4 Materials Selection and Mix Proportioning - Difficulties - ;• 17.3

18. Self Compacting Concrete --^ 18.1 18.1 Introduction - " 18.1 18.2 Definition | 18.2 18.3 Mix Proportion of SCC f 18.2 18.4 Test Methods 18.5 18.5 Acceptance Test Criteria for SCC 18.11 18.6 Production, Placing and Quality Control , . . , : i t;-; . h 18.12 18.7 Effects of Vibrations on Freshly Laid Concrete 18.13 18.8 Other Characteristics of Self-compacting Concrete vs Normal Concrete 18.15 18.9 Advantages of Self-compacting Concrete (SCC) Over Normal

Concrete (NC) 18.15

19. Hot Weather Concrete 19.1 19.1 Introduction . 19.1 19.2 Issues Associated with Hot Weather Concreting 19.1 19.3 Production of Concrete in Hot Weather 19.6 19.4 Placing and Curing 19.6

20. Cold Weather Concrete ^ 20.1 20.1 Introduction , 20.1 20.2 Issues Associated with Cold Weather Concreting f.t ^ i : 20.1 20.3 Production of Concrete in Cold Weather 20.5 20.4 Preparation Before Concreting ^ - . . . 20.7 20.5 Protection of Concrete Against Freezing 20.8 20.6 Protection of Concrete Against Freeze Thaw Effect 20.10

21. Pervious Concrete 21.1 21.1 Introduction , 21.1 21.2 Applications of Pervious Concrete 21.2 21.3 Pavement Applications 21.2 21.4 Surface Course - 21.3 21.5 Parking Lots 21.3

Contents | xv

21.6 Roadways 21.4 21.7 Permeable Bases and Edge Drains 21.4 21.8 Materials • 21.4 21.9 Aggregates 21.5 21.10 Cementitious Materials / 21.5 21.11 Water V v 21.5 21.12 Admixtures \5 21.13 Percolation Rate of Pervious Concrete 21.6 21.14 Pervious Pavement Construction 21.7 21.15 Placing 21.7 21.16 Consolidation " i 21.8 21.17 Jointing ^ ' 21.9 21.18 Testing 21.11 21.19 Pervious Concrete in India 21.11 21.20 Conclusion 21.12

22. Lightweight Concrete 22.1 22.1 Introduction 22.1 22.2 Types of Lightweight Concrete 22.1 22.3 No-Fines Concrete 22.2 22.4 Lightweight Aggregate Concrete 22.3 22.5 Aerated Concrete 22.3 22.6 Testing of Lightweight Concrete 22.4 22.7 Water Absorption 22.4 22.8 Application of Lightweight Concrete 22.5

23. Fibre Reinforced Concrete 23.1 23.1 Introduction of Fibre Reinforced Concrete^__a - 23.1 23.2 Steel Fibre Reinforced Concrete (SFRC) 23.3 23.3 Properties of Different Steel Fibre Types . 23.4 23.4 Synthetic Fibre Reinforced Concrete (SYNFRC) 23.13 23.5 Types of Synthetic Fibres • 23.14 23.6 Dosing _ , ' 23.17 23.7 Glass Fibre Reinforced Concrete 23.20 23.8 Properties of GFRC , ! 23.20

24. High-Density Concrete 24.1 24.1 Heavy Aggregate 24.2 24.2 Special Heavy Aggregate 24.2 24.3 Mix Proportioning, Mixing and Placement of High Density Concrete 24.2

xvi I Contents

25. Underwater Concreting 25.1 Methods of Underwater Placements 25.2 Materials 25.3 Admixtures 25.4 Mix Proportioning 25.5 Concrete Production and Testing 25.6 Tremie Equipment and Placement Procedure 25.7 Placement Procedure 25.8 Direct Pumping 25.9 Concrete Characteristics 25.10 Precautions to be Taken in Underwater Placements 25.11 Go-Devils j 25.12 Laitance 25.13 Cracking 25.14 Detailing 25.15 Antiwashout Admixtures 25.16 Conclusion

26. Mass Concrete and Temperature Rise in Concrete 26.1 Introduction 26.2 Causes of Thermal Cracking 26.3 Methods of Temperature Control 26.4 Choice of Cement System 26.5 Materials and Mix Proportioning 26.6 Calculation for Rise in Temperature

Appendix - I

27. Roller Compacted Concrete 27.1 Materials and Mixture Proportioning for RCC 27.2 Materials 27.3 Construction of RCC Dams

28. Foam Concrete 28.1 Introduction 28.2 Advantages of Foam Concrete 28.3 Applications of Foam Concrete 28.4 Production of Foam Concrete 28.5 The Technique 28.6 Special Applications

25.1 25.1 25.1 25.2 25.2 25.2 25.3 25.3 25.5 25.5 25.5 25.6 25.6 25.7 25.7 25.7 25.8

26.1 26.1 26.2 26.3 26.3 26.4 26.5 26.7

27.1 27.1 27.2 27.9

28.1 28.1 28.1 28.2 28.3 28.6 28.7

Contents | xvii

29. Acid Resistant Concrete

29.1 Introduction v ! 29.2 Acid Resistant Concrete 29.3 Mix Design for ARC Concretes 29.4 New Generation Construction Chemicals for HPC 29.5 Microsilica Slurry for High Performance Concretes ; ,

30. Concrete Composites Containing Polymers

30.1 Introduction , i •• > 30.2 Polymers as a Compositing Material .; ,„ 30.3 Polymer Concrete (PC) ; 30.4 Polymer Modified Concrete (PMC) — TT' 30.5 Polymer-impregnated Concrete (PIC) 30.6 Future Possibilities of Polymer-Cement Composites

31. Concrete Roads and High Volume Fly Ash Concrete

30.1 History of Concrete Roads ,; ; ; ^ 31.2 Advantages of Concrete Roads 31.3 Some Disadvantages of Concrete Roads and How they can be Overcome 31.4 Economics of Concrete Roads vis-a-vis Flexible Pavements 31.5 Design of Concrete Pavements 31.6 Joints in Concrete Roads 31.7 White-topping 31.8 Continuously Reinforced Concrete Pavement (CRCP) 31.9 High Volume Fly-ash Concrete , , 31.10 Construction , .

Appendix I

32. Quality Control and Quality Assurance of Concrete - t> 32.1 Introduction i v j ; - ur 32.2 What are Quality Assurance (QA) and Quality Control (QC)? 32.3 Concrete Industry Scenario 32.4 Regulatory Framework for QA and QC 32.5 Indigenous Quality Scheme 32.6 Check List

33. Non Destructive Testing of Concrete

33.1 Introduction 33.2 The Objective 33.3 Commonly used Test Methods

29.1

29.1 29.2 29.5 29.6 29.8

30.1

30.1 30.1 30.3 30.4 30.7

30.10

31.1

31.1 31.1 31.2 31.3 31.3 31.6

-31.8 k.9 31.9

31.15 31.22

32.1 32.1 32,1

3 U

32.5 32.15

33.1 33.1 33.1 33.5

xviii I Contents

33.4 Sampling and Relibility ; u , 33.22

34. Repair and Maintenance of Concrete 34.1

34.1 Introduction 34.1 34.2 Why Repairs — Introduction ' 7 " ' 34.8 34.3 Injections for Repairs " ' ' 34.15 34.4 Methods of Repairs ; t • 34.25 34.5 Preventive Maintenance i . = : v s ^ i , - : 34.45

35. Concrete and its Environmental Impact 35.1

35.1 CO2 Emission ^ ^ - ^ 3 5 . 2 35.2 CO2 Emissions from Cement ^ J - - ^ ^ - ^ ^ ^ 35.4 35.3 Suggestions to Reduce Environmental Impact 35.4 35.4 A Model for the Future ? a ; , 357

36. Current and Expected Future Advances in Concrete 36.1

36.1 Advances in Concrete Technology 36.1 36.2 Application of Ultra High Strenght Concrete ^ ^ 5 - 352

36.3 Technology Development 36.3 36.4 Ultra Thin White Toppings for Roads 36.10 36.5 Types of Overlay 36.10 36.6 Advantages 36.11 36.7 Features 36.11

37. Summary of Codal Provision for Concrete and Cementitious Materials 37.1

37.1 Introduction 37.1 37.2 Concrete Making Materials 37.1 37.3 Concrete Mix Proportioning 37.9 37.4 Batching and Mixing of Concrete 37.10 37.5 Durability of Concrete ^ 37.14 37.6 Sampling and Strength of Concrete 37.18

About the Authors A.l Index ' • 1.1